Electronic nicotine delivery system

ABSTRACT

A system to generate a vapor from a liquid includes an electric heater and an elongate wick. The electric heater defines an interior void having an inner surface and a plurality of apertures, and it is formed of an electrically resistive material contained within a heat diffusing material. The elongate wick is formed of a durable elongate structure having a plurality of liquid-conducting features on the outer surface. At least a portion of the liquid-conducting features of the elongate wick proximate the first end engage at least a portion of the one inner surface of the electric heater and are capable of conducting a the liquid from a source proximate the second end of the wick along the outer surface of the elongate wick to the electric heater.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.16/220,220 filed on Dec. 14, 2018, which is a continuation of U.S.application Ser. No. 15/525,633 filed on May 10, 2017, which is thenational stage filing under 35 USC 371 of international applicationPCT/EP2015/076883 filed on Nov. 17, 2015, which claims priority to U.S.provisional application 62/080,656 filed on Nov. 17, 2014, the completedisclosures of which are hereby incorporated herein by reference for allpurposes.

FIELD OF THE INVENTION

The present invention relates to a system for the delivery of an aerosolto a human, components thereof, and methods of using the system. Inparticular, the invention relates to a system of generating a vapor froma liquid.

DESCRIPTION OF THE PRIOR ART

Electronic nicotine delivery systems (ENDS) emerged in 2003 and havegrown to become widely available globally (“Electronic Nicotine DeliverySystems: International Tobacco Control Four-Country Survey,” AmericanJournal of Preventive Medicine, VOL. 44, Issue 3, pp. 207-215 (March2013)). These systems replace conventional smoking articles that involvethe combustion of tobacco or other smokable material. The ENDS generallyinvolve the vaporization and/or aerosolization of nicotine, often byheating a nicotine-containing liquid to mimic conventional smokingwithout combustion and generating tar and some of the more dangerousbyproducts of conventional smoking articles.

Some inexpensive products, known as e-cigarettes, on the market deliverthe nicotine-containing liquid to the heater via a fabric saturated withthe liquid (Rose et al., US Pat. App. Pub. No. US2012/0255567 A1). Otherdevices provide a disposable cartridge for the liquid (Philip MorrisProducts S.A., Eur. Pat. App Pub. No. EP 2 113 178 A1). In some suchproducts, the liquid saturates a sponge material that helps to transportit to the heater. Other systems incorporate an inexpensive glass fiberbundle wick to transport the liquid from the heater (Philip MorrisProducts, S.A., Eur. Pat. App. Pub. No. EP2 606 756 A1). The wick itselfis often integrated with an electric heater (Tucker et al., US Pat. App.Pub. No. US2013/0192615 A1). Thus, the liquid, wick and heater are allelements of the disposable cartridge. The combination of the wick andheater in the disposable cartridge tends to result in low cost, barewire heaters wrapped around the wick to minimize cost in the disposablecomponents.

There have also been attempts to use the e-cigarette technology foractual smoking cessation regimens and/or nicotine replacement therapy.Examples of these uses are disclosed in Rose et al., US Pat. App. Pub.No. US2012/0255567 A1; and Juster et al., US Pat. App. Pub. No.US2013/0340775A1; and Wensley et al., US Pat. App. Pub. No. US2014/0144429 A1.

SUMMARY OF THE INVENTION

Surprisingly, we have found a novel system to generate a vapor from aliquid. One element of the systems includes an electric heater and anelongate wick. The electric heater includes a body comprising at leastone sidewall that defines an interior void, at least one inner surface,at least one outer surface, and a plurality of apertures through the atleast one sidewall, and it is formed of an electrically resistivematerial contained within a heat diffusing material. The elongate wickhas a longitudinal axis, a first end, a second end, and an outersurface, and it is formed of a durable elongate structure having aplurality of liquid-conducting features on the outer surface. At least aportion of the liquid-conducting features of the elongate wick proximatethe first end engage at least a portion of the at least one innersurface of the electric heater and at least a portion of theliquid-conducting features of the elongate wick are capable ofconducting a the liquid from a source proximate the second end of thewick along the outer surface of the elongate wick to the electricheater.

Another embodiment of the invention relates to an elongate wick usefulin a system for generating a nicotine-containing vapor. The wickincludes a solid, elongate structure having a longitudinal axis, a firstend and a second end, a plurality of longitudinally extending channelsdefined by longitudinally extending ribs formed on the outer surface ofthe elongate structure, and an inner bore disposed along thelongitudinal axis of the elongate structure. The channels are arrangedand configured to transport a liquid along the elongate wick, and thediameter of the inner bore is greater than a distance separatingadjacent longitudinally extending ribs.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an assembled electronic nicotinedelivery system (“ENDS”) according to one embodiment of the presentinvention.

FIG. 2A is a longitudinal cross-section of the ENDS of FIG. 1 with thecartridge aligned for insertion into the housing.

FIG. 2B is a longitudinal cross-section of the assembled ENDS of FIG. 1.

FIG. 3 is a cross-section of a disposable cartridge useful in the ENDSof FIG. 1.

FIGS. 4A-4G are schematic views of the movement of air through an ENDS,the formation of a nicotine aerosol, and the movement of the aerosoltoward a mouthpiece of an ENDS.

FIG. 5A is a schematic cross section of an electric heater and baseplateuseful in an ENDS of the present invention.

FIG. 5B is art end view of the electric heater and baseplate of FIG. 5A.

FIG. 5C is a top view of the electric heater and baseplate of FIG. 5A.

FIG. 6A is a schematic view of a green ceramic substrate useful in theformation of an electric heater of the present invention.

FIG. 6B is a perspective view of a multilayered green ceramic heaterelement formed from the substrate of FIG. 6A.

FIG. 7 is a cross-section of the disposable cartridge of FIG. 3 prior tothe insertion of an elongate wick into the reservoir.

FIG. 8 is a cross-section of alternate embodiment of the disposablecartridge similar to that of FIG. 3 prior to the insertion of anelongate wick into the reservoir.

FIG. 9 is a perspective view of the disposable cartridge of FIG. 8.

FIG. 10A is a perspective view of an elongate wick useful in thepractice of the present invention.

FIG. 10B is a cross-section of the elongate wick of FIG. 10A.

FIG. 10C is an enlargement of a portion of the cross-section of FIG.10B.

FIG. 11 is a perspective view of a multilayered green ceramic heaterelement formed about a ceramic wick mandrel.

FIG. 12A is a perspective view of an alternative embodiment of the ENDSof the present invention.

FIGS. 12B-E are cross-sections of the ENDS of FIG. 12A and a containerduring the loading of a disposable cartridge into the receptacle of theENDS housing.

FIGS. 13A-C are cross-sections of the ENDS and a container during theunloading of a disposable cartridge from the receptacle of the ENDShousing.

FIG. 14 is a perspective view of an alternative multichamberedcontainer.

FIG. 15A is a perspective view of an alternative ENDS.

FIG. 15B is a cross-section of the mouthpiece and disposable cartridgeof the ENDS of FIG. 15A.

FIG. 16A is a perspective view of an alternative ENDS.

FIG. 16B is a cross-section of the mouthpiece and disposable cartridgeof the ENDS of FIG. 16A.

FIG. 17A is a perspective view of an alternative ENDS.

FIG. 17B is a cross-section of the mouthpiece and disposable cartridgeof the ENDS of FIG. 17A.

FIG. 18A is a perspective view of an alternative ENDS.

FIG. 18B is a cross-section of the mouthpiece and disposable cartridgeof the ENDS of FIG. 18A.

DETAILED DESCRIPTION OF THE INVENTION

A more particular description of the invention, briefly summarized abovemay be had by reference to the embodiments thereof that are illustratedin the appended drawings. It is to be so noted, however, that theappended drawings illustrate only typical embodiments of the inventionand, therefore, are not to be considered limiting of its scope, for theinvention may admit to other equally effective embodiments.

As used herein the specification and the claims, the term “non-porous”and variants thereof relate to a solid physical structure that iscapable of interaction with liquid without ingress of such liquids intothe solid structure. This can be achieve, for example, with a solidstructure that simply has no pores to permit liquid ingress or byaltering the surface of an otherwise porous structure with animpermeable coating material or a surface treatment that essentiallycloses surface pores. Substantially all fluid transport along such astructure occurs on the outer surfaces thereof, not through thestructure, itself.

As used herein the specification and the claims, the term “thermaldegradation” and variants thereof relate to damage or destruction in thepresence of elevated temperatures. This includes combustion, charring,melting, deformation, destruction, off-gassing of toxic or otherdangerous substances, and the like.

As used herein the specification and the claims, the term “durable” andvariants thereof relate to the ability of a structure to resist damage,wear, friability, distortion, buckling, and/or destruction while beingsubjected to friction during sliding motions along adjacent structuresand into interference fittings.

Referring to FIGS. 1-3, the electronic nicotine delivery system (“ENDS”)10 includes a power source 12 and an electric heater 14 contained withina housing 16. The housing 16 has at least one air inlet 17 and providesa receptacle 18 for a disposable cartridge 20 proximate the electricheater 14. The disposable cartridge 20 preferably includes a reservoir22 containing a nicotine solution and a mouthpiece 24 having an outlet25 for drawing a nicotine aerosol from the ENDS 10. At least whenassembled, the housing 16, electric heater 14, and cartridge 20cooperate to form a vaporization chamber 26. The assembled ENDS 10 alsoprovides a predetermined airflow from the at least one air inlet throughthe vaporization chamber 26, an outlet conduit 28 and to the outlet 25of the mouthpiece 24 to permit a user to inhale the nicotine aerosolformed therein. In addition, the assembled ENDS 10 provides a liquidconduit from the reservoir 22 to the electric heater 14, preferably anelongate wick 30. The housing 16 may also provide for connectivity to anoutside electrical source and/or data communication, such as a USB port32, to supply and/or resupply the internal power source 12, preferably arechargeable battery.

The internal power source 12 is sufficient to power the electric heater14, a programmable controller (not shown), and any desired feedback to auser (e.g., light 33), external computer, or network. The programmablecontroller receives information from a pressure sensor 34 (detectinginhalation by a user), and, possibly, other sensors (such as temperaturesensors) to control the power delivered to the electric heater 14, andcontrols optional over temperature sensor(s), which can terminate powerto the electric heater 14 to prevent undesirable and/or dangerousthermal events. The programmable controller can provide for datacollection, storage and communication to the external computer. This canbe communicated through a wired or wireless connection. The internalpower source 12 can be any appropriate portable power source 12.

The electric heater 14 is mounted on a base plate 36 to isolateelectrical resistance heater elements from other, thermally sensitivecomponents of the ENDS 10. The electric heater 14 comprises at least oneelectrical resistance heater element contained in a heat diffusingmaterial. The diffusion of the heat through the heat diffusing materialgenerally evens out heat profile generated by the heating element(s) toprevent the formation of localized hot spots on the electric heater 14surface.

As indicated above, the disposable cartridge 20 preferably includes areservoir 22 containing a nicotine solution and a mouthpiece 24 fordrawing a nicotine aerosol from the ENDS 10. In addition, the assembledENDS 10 provides a liquid conduit from the reservoir 22 to the electricheater 14. In a preferred embodiment, the liquid conduit is an elongatewick 30 extending from the reservoir 22 to the electric heater 14. Theelongate wick 30 intimately contacts the electric heater 14 surface toenable the thermal energy to vaporize the nicotine solution transportedthereto by the elongate wick 30. As the nicotine solution is vaporized,the elongate wick 30 transports additional nicotine solution to theelectric heater 14 through capillarity.

The assembled ENDS 10 also provides a vaporization chamber 26 proximatethe electric heater 14. It is in the vaporization chamber 26 that theelectric heater 14 vaporizes the nicotine solution transported by theelongate wick 30 and in which the vaporized nicotine solution combineswith outside air drawn in through one or more inlet ports 17 to form anicotine aerosol. The vaporization chamber 26 also communicates with theoutlet 25 of the mouthpiece 24 via at least one outlet conduit 28 in thedisposable cartridge 20 to permit a user to draw the nicotine aerosolinto his or her mouth.

FIGS. 4A-4G illustrate one example of an air flow through the ENDS 10.These figures are schematic to explain the process and are not intendedto be limiting of the actual location of all elements disclosed therein.As shown in FIG. 4A, when a user draws air from the mouthpiece, thenegative pressure causes air to flow into the assembled ENDS 10. Inparticular, air is withdrawn from the vaporization chamber 26 throughthe outlet conduit 28, lowering the air pressure in the chamber 26. Thewithdrawn air (indicated by arrows 38) is replaced via air inlet throughone or more holes 17 in the housing 16 proximate the vaporizationchamber 26 (FIG. 4B). The inlet air is indicated by arrows 39. Thelowered air pressure in the chamber 26 is sensed by a pressure sensor 34disposed proximate the base plate 36, outside of the vaporizationchamber 26 via a pressure equalization port 40. As shown in FIG. 4C, theequalization of pressure through pressure equalization port 40 distortsisolation membrane 42 to lower air pressure proximate the pressuresensor 34 to activate an operatively coupled switch with pressure sensor34. This pressure sensor 34 activates the electric heater 14, which inturn heats the nicotine solution in contact therewith on the surface ofthe wick 30. The nicotine solution is vaporized and combined with air inthe vaporization chamber 26, forming a nicotine aerosol 44 (shown inFIG. 4D). The nicotine aerosol 44 is evacuated from the vaporizationchamber 26 through the outlet conduit 28 and delivered to the mouthpiece24 and, ultimately, the user's mouth (FIG. 4D). As the nicotine solutionis vaporized, additional solution is drawn from the reservoir 22 alongwick 30 to electronic heater 14 as shown by nicotine solution transportarrows 46. The volume of nicotine solution removed from reservoir 22 isreplaced by air 48 (indicated by arrows) drawn through the inner bore 50of wick 30 (FIG. 4E), described in further detail, below. In oneembodiment, after a predetermined time (e.g., determined by theprogrammable controller), the power to the electric heater 14 isterminated, the vaporization chamber 26 cools, and no further nicotineaerosol is formed (FIG. 4F). The user will then stop drawing on the ENDS10, ending his/her “treatment” (FIG. 4G). Alternatively, the user maystop drawing on the device prior to the predetermined time. In such acase, the pressure in the vaporization chamber 26 will return toatmospheric pressure, the isolation membrane 42 will relax, and pressuresensor 34 will signal switch to terminate power to the electric heater14.

The disposable cartridge 20 has a number of features to increase thesafety of the system. In one embodiment, the disposable cartridge 20securely locks into the housing 16 in a manner that it is not easilyremoved by hand; removal from the housing 16 requires interaction with acontainer (described in greater detail, below) for the disposablecartridge 20. In a further embodiment, the disposable cartridge 20 isnot easily re-fillable with another liquid. In another embodiment, anunused disposable cartridge 20 is locked in a container until use;removal from the container requires interaction with an empty ENDS 10housing 16. Thus, the disposable cartridge 20 is secured by either theENDS 10 for use or a container (described in greater detail, below) forstorage and/or disposal. This greatly reduces the potential forunintended exposure of the nicotine solution to the environment and/orchildren as this design significantly reduces the ability to access thenicotine solution contained in the disposable cartridge 20. This issubstantially through use of the ENDS 10 and the conversion of thenicotine solution to an aerosol. It is difficult to otherwise access theliquid contents when the cartridge is secured in either the ENDS 10and/or container containing the disposable cartridge 20.

The ENDS 10 can be used with accessories such as a charging case, whichmay include additional power supply and electronics.

Housing:

The housing 16 may comprise any suitable material or combination ofmaterials. Preferably, it includes one or more hard, heat-resistantmaterial(s). Examples of suitable materials include, without limitation,metals, alloys, plastics or composite materials containing one or moreof those materials, or ceramics. Plastics can include thermoplasticsthat are suitable for food or pharmaceutical applications, for example,polypropylene, polyetheretherketone (PEEK) and polyethylene. Preferably,the material is light and non-brittle. The housing 16 may be fabricatedby plastic injection molding, or any other suitable technique, and it ispreferably ergonomic and adapted to fit comfortably in a hand of a user.In one embodiment, the housing 16 may have a maximum length dimension ofup to about 20 cm and a maximum dimension perpendicular to the length ofup to about 10 cm.

Power Source:

The internal power source 12 is sized to provide sufficient power forthe electric heater 14 that vaporizes the nicotine solution and anyother electronic controls included in the assembled ENDS 10. It ispreferably replaceable and/or rechargeable and may include devices suchas a capacitor or, more preferably, a battery. In a presently preferredembodiment, the power source 12 is a replaceable and/or rechargeablebattery, although it could include a quick-discharging capacitor powersource 12 that is charged by one or more battery cells. Thecharacteristics required of the power source 12 are selected in view ofthe characteristics of all components in the ENDS 10. Preferredrechargeable battery cells include, without limitation, lithium-basedcells, including lithium polymer batteries. One example of an internalpower source 12 is a lithium polymer cell providing a voltage of about3.4 V that has a capacity of at least about 200 milliamp hours (mAh).

The internal power source 12 is preferably in electrical communicationwith a coupler (such as a USB port 32) for connectivity to an outsideelectrical source. However, a preferred system prevents the user fromusing the ENDS while charging the device. This coupler can also providefor information transfer between an internal process controller andexternal networks and or computing devices including, withoutlimitation, a smart charging case, smart phone, portable computingdevice, desktop computer, or the internet or other local and/or widearea networks.

Electronics:

In one embodiment, as described in FIGS. 4A-4G, the pressureswitch/sensor 34 in the electronic control circuit is configured todetect the drawing of air through ENDS 10, especially through thevaporization chamber 26, and an electric circuit is closed between theinternal power source 12 and the electric heater 14. The processcontroller controls an amount of voltage/current to be delivered to theelectric heater 14. The electric heater 14 outputs a sufficient amountof heat to vaporize at least a portion of the nicotine solution, whichthe user then draws as a nicotine aerosol 44. When the user ceases todraw air through the mouthpiece 24 and air outlet, the pressure sensor34 detects the lack of airflow (or pressure drop) in the vaporizationchamber 26, and the electric circuit between the internal power source12 and electric heater 14 is opened (e.g., directly by the pressuresensor 34 or responsive to receipt of instructions from the processcontroller) with or without delay circuitry built into the control.Manual switching or activation of the power source 12 is also an option.

In one embodiment, process controller can be a microchip or controllerthat operates as desired when used by the user. Thus, the processcontroller can receive readings from the switch/sensor 34, and can causethe voltage/current to be supplied to the electric heater 14 as afunction of such readings. The switch/sensor 34 can be a switch, asensor, or a combination of a switch and sensor. For instance, theswitch/sensor 34 may comprise an electronic airflow sensor, wherein theelectronic airflow sensor senses when the user is drawing on the ENDS10. Still further, the switch/sensor 34 may comprise a timed switch thatopens the circuit between the internal power source 12 and the electricheater 14 after the circuit has been closed for a threshold amount oftime. There are a variety of switches and sensors that can be used todetect air flow and/or pressure that can be utilized to activate theheating element.

In addition, signaling elements, such as lights (e.g., signal light 33),sounds, and/or scents can be included in and/or controlled by theelectronic control circuitry.

Electric Heater:

In one embodiment, the electric heater 14 includes a base plate 36 andan electric heater 14. The base plate 36 operates as a mounting surfacefor the electric heater 14 and a thermal barrier between thevaporization chamber 26 and other housing 16 components, such ascontrollers/control circuitry and/or the internal power source 12. Asshown in FIG. 5A, the base plate 36 can provide one or more air passages(e.g., pressure equalization port 40 and air inlet passage 52). The baseplate 36 also provides one or more passageways for electrical conductorsto connect the electric heater 14 to the internal power source 12.

Generally, any material that can be machined, or more preferably molded,to the desired shape and that can withstand chemical degradation by theliquids used in the system and high temperatures (e.g., in excess of150° C. or even 200° C.) can be used to make the base plate. Preferredmaterials include, without limitation, thermoset polymers, thermoplasticpolymers, and ceramics. Particularly preferred materials includeceramics and heat-resistant thermoplastic polymers. A representative,non-limiting list of useful heat-resistant thermoplastic polymersinclude liquid crystal polymers (“LCP”), Polyetheretherketone (PEEK),Polyether Imide (PEI), Polyphenylene Sulfide (PPS), fluorpolymers,Polyimides, Polyamideimides (PAIs), High-performance polyamides (HPPAs),Polyimides (PIs), Polyketones, Polysulfone derivatives, Polycyclohexanedimethyl-terephthalates (PCTs), Fluoropolymers, Polyetherimides (PEIs),Polybenzimidazoles (PBIs), Polybutylene terephthalates (PBTs),Syndiotactic polystyrene, Acrylonitrile-Methyl acrylate copolymers (forexample Barex® resins Velox, Hamburg, Germany), and the like.

The electric heater 14 includes electrical resistance heater elementssubstantially encapsulated within a substantially non-porous ceramicmaterial, the heat diffusing material. The non-porous nature of theceramic material encapsulating the heater elements substantiallyeliminates direct contact between the nicotine solution and theresistance heater elements. This minimizes the formation of localizedhot spots on the electric heater 14 surface that contact the nicotinesolution. This reduces the likelihood of overheating of both thecomponents of the nicotine solution and the elongate wick 30. Indeed,this permits the use of wicks that cannot operate directly contact withmetallic, resistance heating elements, such as tungsten and/or copperwire. Many commercial devices employ bundles of glass fibers as wicks,and these wicks are wrapped with bare metal wires. Examples described inpatent literature include Philip Morris Products, S.A., Eur. Pat. App.Pub. No. EP2 606 756 A1; and Tucker et al., US Pat. App. Pub. No.US2013/0192615 A1. In contrast, the present invention permits the use ofa polymeric wick, even an extruded wick formed of substantiallynon-porous, durable, thermoplastic material, as described below.

In one preferred embodiment, the electric heater 14 includes resistanceheater elements formed of electrically resistive materials encapsulatedin a substantially non-porous ceramic material. The electricallyresistive materials may be in the form of a wire, flakes, foil or film,a continuous or patterned coating, and the like deposited (e.g.,printed, sprayed, coated, and the like) or formed on a ceramic materialthat is further processed to encapsulate (and fuse, as appropriately)the electrically resistive material in the ceramic material.

Suitable electrically resistive materials include but are not limitedto: semiconductors such as doped ceramics, electrically “conductive”ceramics (such as, for example, molybdenum disilicide), carbon,graphite, metals, metal alloys and composite materials made of a ceramicmaterial and a metallic material. Such composite materials may comprisedoped or undoped ceramics. Examples of suitable doped ceramics includedoped silicon carbides. Examples of suitable metals include titanium,zirconium, tantalum and metals from the platinum group. Examples ofsuitable metal alloys include stainless steel, nickel-, cobalt-,chromium-, aluminum-titanium-zirconium-, hafnium-, niobium-,molybdenum-, tantalum-, tungsten-, tin-, gallium-, manganese- andiron-containing alloys, and super-alloys based on nickel, iron, cobalt,stainless steel, Timetal® titanium alloy, and iron-manganese-aluminumbased alloys.

In one embodiment, the electrically resistive material may take the formof a metallic etched foil (or film) encapsulated between two layers ofan inert, heat diffusing material. In that case, the inert material maycomprise Kapton® polyimide or mica foil. The etched foil may comprise ametal sheet cut by a laser or by electro-chemical process and formedinto a desired pattern. The sheet may be rectangular in shape, or mayhave a patterned shape which may form a coil-like structure when rolledaround the capillary wick 30. Other alternatives include a heating wireor filament, for example a Ni—Cr, platinum, tungsten or alloy wireembedded in the ceramic material.

In one preferred embodiment shown in FIGS. 6A-B, the electric heater 14employs tungsten-doped material as the electrically resistive material54 formed on a green (un-fired) ceramic substrate 56. Preferably, thematerial is printed or coated onto the green ceramic substrate. Apreferred green ceramic substrate 56 is formed having a pattern of macroapertures 58 formed therein. A trace of the electrically resistivematerial 54 is deposited in a continuous path on a portion of a greenceramic substrate 56, beginning and ending at one edge 60 of the greenceramic substrate 56. The green ceramic substrate 56 is then wrappedabout a cylindrical mandrel 62 (in the direction indicated by arrow 63)to form a green ceramic heater element 64 with open ends 66 formed ofthree layers of the green ceramic substrate 56, each layer superposed ona preceding layer with the apertures 58 substantially indexed to providecontinuous macro apertures from the outer surface 68 of the greenceramic heater element 64 to its resulting inner bore 70. Theelectrically resistive material 54 is encapsulated within the layers ofthe green ceramic heater element 64, and two electrical tabs 72 areprovided in electrical contact with the ends of the electricallyresistive material 54. These tabs are then available for electricalconnection through the base plate 36, as described above. The greenceramic heater element 64 is then fired (heated to very high temperatureto fuse the ceramic material) to form the electric heater 14, as will berecognized by those of ordinary skill in the art.

In an alternative embodiment, the macro apertures 58 may be formed afterthe green ceramic substrate 56 is wrapped about the mandrel 62.

More generally, the electric heater has a body formed of at least onesidewall that defines a length, an interior void, at least one innersurface (e.g., the inner bore 70), at least one outer surface (e.g., theouter surface 68), and a plurality of apertures 58 through the at leastone sidewall and/or between adjacent sidewalls connecting the innersurface 70 and the outer surface 68. Thus, the nicotine vapor can toescape the heater/wick combination from the inner bore 70 through themacro apertures 58 into the volume of the vaporization chamber 26.

The electric heater can take many shapes that provide inwardly- andoutwardly-directed surfaces. For example, a simple tubular structure hasbeen described. Other tubular structure can include those with circular,elliptical polygonal and other closed cross-sections. Alternative formsof the heater can be include channel heaters that have an open wall toprovide a cross-section of a “c-shape”, a “u-shape”, a “v-shape”, orother open, channel structures. Alternatively, the body may be formed ofa plurality of fingers, each providing a sidewall, and the sidewallscollectively define the interior void.

In addition, the maximum dimension perpendicular to the electric heaterlength (e.g., a diameter of a tubular electric heater) can vary toprovide a conical or frusto-conical shape or other socket-like shapes toaccept or to hold a wick in intimate contact with the inwardly-directedsurface.

Cartridge:

As indicated above, the housing 16 provides a receptacle 18 for thedisposable cartridge 20 proximate the electric heater 14, and thedisposable cartridge 20 includes a reservoir 22 containing a nicotinesolution. While the following description references a nicotinesolution, other, vapor-forming solutions can be employed in the deviceof the present invention.

Generally, nicotine solutions include at least a combination of water,propylene glycol and/or glycerin, and nicotine. In some cases, solutionsmay include from about 2 to about 10 wt-% nicotine, from about 0 toabout 30 wt-% water, from about 65 to about 95 wt-% propylene glycoland/or a mixture of propylene glycol and glycerin. These solutions havea boiling point of between about 105° C. and about 150° C., a viscosityof between about 10,000 and about 60,000 mPas (milli-pascals). In oneembodiment, a nicotine solution includes at least 12 percent by weightof water, at least 70 percent by weight of propylene glycol; and atleast 2 percent by weight of nicotine or a salt thereof. In oneembodiment, the liquid formulation contains at least 15 percent byweight of water, such as at least 20 percent by weight of water. In oneembodiment, the liquid formulation contains at least 75 percent byweight of propylene glycol, such as at least 80 percent by weight ofpropylene glycol, such as at least 85 percent by weight of propyleneglycol.

As shown in FIG. 7, the reservoir 22 includes at least one port 74 fromwhich the nicotine solution can be withdrawn and directed to thevaporization chamber 26 in the assembled ENDS 10. However, prior to use,a liquid barrier or seal, such as a barrier membrane 76 is disposed toprevent leakage of the solution through the port 74. In embodiments inwhich the elongate wick 30 is incorporated into the disposable cartridge20, the elongate wick 30 can be stored, such as slidably fitted in theport 74, adjacent the barrier membrane 76, and during the locking of thedisposable cartridge 20 into the receptacle 18, the elongate wick 30 canslide further into the reservoir 22 to rupture the barrier membrane 76to provide the liquid conduit from the reservoir 22 to the electricheater 14. The penetration of the wick 30 into the reservoir 22 can belimited by means of a stop 77 (shown in FIGS. 3 and 7). In analternative embodiment (not shown), the liquid barrier may be a seal orplug disposed about the distal end of the wick that is disposed in theport 74. In embodiments in which the elongate wick 30 extends from theelectric heater 14, wick 30 would slide into the port 74 and rupture thebarrier membrane 76 or break a seal at or proximate the port 74 duringthe locking of the disposable cartridge 20 into the receptacle 18. Inalternative embodiments in which the wick is a part of replacement kitfor the ENDS, the wick can be packaged with a disposable cartridge andinserted into the port 74 prior to securing the disposable cartridge tothe receptacle of the housing.

As the nicotine solution is withdrawn from the reservoir 22, an equalvolume of air is admitted into the reservoir 22. This replacement airmay be provided through one or more vents (such as inner bore 50 of wick30) or other reservoir vent technology known to those of ordinary skillin the art.

The disposable cartridge 20 also includes at least one air passage(outlet conduit 28) between the vaporization chamber 26 and themouthpiece 24 to permit a user to draw the nicotine aerosol into his orher mouth. The outlet conduit 28 may have a substantially constantcross-section, or the cross-section may vary along its length. In onepreferred configuration, the cross-sectional area of the outlet conduit28 decreases away from the vaporization chamber 26. The mouthpiece 24 ispreferably disposed at a portion of the disposable cartridge 20 distalto the vaporization chamber 26.

While the embodiment of FIGS. 1-7 is effective, one of ordinary skill inthe art will recognize that more symmetry of airflow around the heatercan improve particle size distribution and reduce the likelihood ofcondensation in the vaporization chamber. Thus, more than one outletconduits may be employed or the outlet conduit may be in the form of anannulus. Preferably, there are at least two outlet conduits (as shown inFIGS. 8 and 9), the disposable cartridge 20′ includes two air passages(outlet conduits 28′) between the vaporization chamber 26′ and themouthpiece 24′ to permit a user to draw the nicotine aerosol into his orher mouth. Again, the two outlet conduits 28′ may have a substantiallyconstant cross-section, or the cross-section may vary along theirlength. As above, the cross-sectional area of the outlet conduits 28′may decrease away from the vaporization chamber 26′. The mouthpiece 24′is preferably disposed at a portion of the disposable cartridge 20′distal to the vaporization chamber 26′. In summary, the disposablecartridge includes at least one outlet conduit (outlet conduit 28 inFIGS. 3 and 7). More preferably, the disposable cartridge mayincorporate two (outlet conduits 28′ in FIGS. 8 and 9). Even morepreferably, the disposable cartridge incorporates 2 to 8 outlet conduitsto improve the symmetry of air flow through and out of the vaporizationchamber.

In addition, as shown in FIGS. 8 and 9, the outlet conduits 28′ may havea decreasing cross-section towards the mouthpiece. While not intendingto be held to this theory, it is believed that a tapered outlet conduitmay provide increase velocity as the aerosol is drawn from the ENDS.This increased velocity may reduce the likelihood of condensation beingdeposited in the cartridge or mouthpiece. The tapered outlet conduit mayalso provide compression to maintain the temperature of the aerosol tominimize condensation.

In one embodiment, the disposable cartridge 20 has a number of featuresto increase the safety of the system. As will be described in greaterdetail below, embodiments of the disposable cartridge 20 incorporatesfeatures to enable it to securely lock into the receptacle 18 of thehousing 16 in a manner that it removable by hand without damage to thedisposable cartridge 20, the housing 16, or preferably both. Inaddition, the disposable cartridge 20 incorporates features to enable itto securely lock into a container prior to use and after use, fordisposal.

While the cartridge has been described in the context of a nicotinedelivery system, alternative active ingredients may be employed in thissystem, such as drugs to treat asthma, pain, and other inhalably-treatedconditions.

Vaporization Chamber:

The vaporization chamber 26 is defined by elements of the disposablecartridge 20, the housing 16, and the electric heater 14. In particular,the electric heater 14 is functionally at the center of the vaporizationchamber 26. It is at the interface between the electric heater 14 andthe nicotine solution that a nicotine-containing vapor is formed andadmixed with air to form a nicotine aerosol. In the embodiment shown inFIG. 2, the base plate 36 forms one wall of the vaporization chamber 26,and an end 78 of the disposable cartridge 20 forms an opposite wall ofthe vaporization chamber 26. The remaining walls of the vaporizationchamber 26 are formed by the housing 16. At least one, and preferably aplurality of holes 17 are formed in the housing 16 proximate thevaporization chamber 26. In a preferred embodiment shown in FIG. 5, theair holes 17 communicate, via manifold (shown as annular passage 80),with air inlet passages 52 in the base plate 36 that are angled from thelongitudinal axis of the vaporization chamber 26 to create a circularair flow or vortex (illustrated by arrows 81 in FIG. 5B) about theelectric heater 14 in the vaporization chamber 26. These air inletpassages 52 provide a plurality of vaporization chamber air inletopenings 53. It is believed that this improves mixing of the nicotinevapor and inlet air to form a more uniform nicotine aerosol that can bedrawn through the vaporization chamber air outlet conduit 28 and to themouthpiece 24.

While the above description refers to providing a vortex flow about theheater, one of ordinary skill in the art will recognize that alternativeair flows are possible and may be selected for different desiredattributes.

Generally, any material that can be machined, or more preferably molded,to the desired shape and that can withstand chemical degradation by theliquids used in the system and high temperatures can be used to makecomponents of the vaporization chamber. Preferred materials include,without limitation, thermoset polymers, thermoplastic polymers, andceramics. Particularly preferred materials include ceramics andheat-resistant thermoplastic polymers. A representative, non-limitinglist of useful heat-resistant thermoplastic polymers include liquidcrystal polymers (“LCP”), Polyetheretherketone (PEEK), Polyether Imide(PEI), Polyphenylene Sulfide (PPS), fluorpolymers, Polyimides,Polyamideimides (PAIs), High-performance polyamides (HPPAs), Polyimides(PIs), Polyketones, Polysulfone derivatives, Polycyclohexanedimethyl-terephthalates (PCTs), Fluoropolymers, Polyetherimides (PEIs),Polybenzimidazoles (PBIs), Polybutylene terephthalates (PBTs),Syndiotactic polystyrene, Acrylonitrile-Methyl acrylate copolymers (forexample Barex® resins Velox, Hamburg, Germany), and the like.

Wick:

In addition, the assembled ENDS 10 provides a liquid conduit from thereservoir 22 to the electric heater 14. In a preferred embodiment, theliquid conduit is an elongate wick 30 extending from the reservoir 22 tothe electric heater 14. The elongate wick 30 intimately contacts theelectric heater 14 surface to enable the thermal energy provided by theelectrical resistance heater elements to vaporize the nicotine solutiontransported thereto by the elongate wick 30. As the nicotine solution isvaporized, the elongate wick 30 transports additional nicotine solutionto the electric heater 14 through capillarity.

In one preferred embodiment shown in FIG. 3, the elongate wick 30 is acomponent of the disposable cartridge 20, and it is formed ofsubstantially non-porous durable thermoplastic material. This wick 30structure is capable of being inserted into the inner bore 70 of anopen, cylindrical electric heater 14 to create an intimate contactbetween the outer surfaces of the elongate wick 30 and the innersurfaces of the electric heater 14. Thus, the elongate wick 30 of thepresent invention is sufficiently rigid and robust to resist damage andsignificant distortion while moving axially with respect to the innersurfaces of and electric heater and/or with respect to the port of thedisposable cartridge. Such a wick is preferred over wicks formed ofbundles of glass fibers currently used in many electronic nicotinedevices, as such fibers are likely to be broken off in the interferencefit with the cylindrical heater element. The broken fiber fragmentswould be free to become entrained in the air stream and then possiblyinto a user's lungs.

An example of this preferred wick structure is shown in FIGS. 10A-C as atubular durable thermoplastic material having a plurality ofliquid-conducting features, such as longitudinally extending ribs 82projecting from the outer surface thereof. This provides capillarychannels between the ribs 82 to conduct the nicotine solution along theouter surface of the elongate wick 30 from the reservoir 22 to thecylindrical electric heater 14. In one embodiment, the dimensions of theinner bore 50 of the elongate wick 30 are selected to discouragecapillary transport of the nicotine solution through the inner bore 50and to permit air to be drawn into the reservoir 22 to equalize pressureas nicotine solution is removed therefrom (as shown in FIG. 4E). Such anelongate wick 30 can be formed by extruding the plastic through one ormore dies. One preferred form of extrusion includes extruding thecentral tube and co-extruding the ribs 82 onto the surface of the tube.

The material selected for the wick can be any material that can beformed to be sufficiently rigid to withstand the forces involved inslidably engaging other components of the ENDS, including the electricheater 14, the disposable cartridge port 74. It also should be resistantto thermal degradation up to a temperature of at least about 180° C.Preferably, the material is resistant to thermal degradation up to atemperature of at least about 200° C., and more preferably, at leastabout 250° C.

Generally, any material that can be machined, or more preferably molded,to the desired shape and that can withstand chemical degradation by theliquids used in the system and the high temperatures discussed above canbe used to make the wick, and it is preferred that the materials havelow thermal conductivity to avoid overheating liquid in the reservoir22. Preferred materials for the elongate wick include thermosetpolymers, thermoplastic polymers, and ceramics. Particularly preferredmaterials include ceramics and heat-resistant thermoplastic polymers. Arepresentative, non-limiting list of useful heat-resistant thermoplasticpolymers include liquid crystal polymers (“LCP”), Polyetheretherketone(PEEK), Polyether Imide (PEI), Polyphenylene Sulfide (PPS),fluorpolymers, Polyimides, Polyamideimides (PAIs), High-performancepolyamides (HPPAs), Polyimides (PIs), Polyketones, Polysulfonederivatives, Polycyclohexane dimethyl-terephthalates (PCTs),Fluoropolymers, Polyetherimides (PEIs), Polybenzimidazoles (PBIs),Polybutylene terephthalates (PBTs), Syndiotactic polystyrene, and thelike. Preferred materials include PEEK, PEI, LCP (for example Vectra®liquid crystal polymers available from Celanese), and the like.

As can be seen from FIG. 10B, the diameter “d_(i)” of the inner bore 50is much greater than the spacing “s” between adjacent ribs 82 on theouter surface of the elongate wick 30. The spacing “s” and height “h” ofthe ribs 82 is selected to effectively transport the nicotine solutionin the channels 84 formed between adjacent ribs. The height “h” ismeasured from the base of the channel 84 between ribs and the outermosttip of the rib. The spacing “s” is measured between adjacent ribs at 90%of their height. It will also be recognized that the transportproperties of the channels 84 can be modified, as desired, byappropriate surface treatment (including coatings) to improve thewettability of the surfaces of the channel by the nicotine solution. Theheight “h” of the ribs is also determined by the effectiveness of heattransfer from the inner bore 70 of the electric heater 14 to thenicotine solution transported by the channels 84, as the inner bore 70of the electric heater 14 will be in contact with or at least in closeproximity to the outer ends 86 of the ribs 82 during use. While thesurface of the heater elements and the liquid surface do not have to bein contact, we have found that the system tolerates a gap between theouter ends of the ribs and the heater element. Preferably, the gap isless than about 0.3 mm, and more preferably, the gap is less than about0.2 mm. It is believed that the gap between the heater element and thenicotine solution is quickly filled with saturated vapors and such a gapcan therefore conduct heat from the heater surface to the liquid betterthan a dry air gap.

As indicated above, the inner bore 50 of the elongate wick 30 serves topermit air ingress into the reservoir 22 to equalize pressure asnicotine solution is removed. Unfortunately, under some conditions, theinner bore 50 may also provide a potential pathway for leakage of thenicotine solution therethrough, so the surface of the inner bore 50 maybe treated (either by coating or physical surface treatments) to reduceits wettability by the nicotine solution. Alternatively, a check valve(not shown) may be used to permit air ingress through the bore 50 andprevent undesired nicotine solution leakage. In one embodiment, thesurfaces of the heater 14 that contact the wick 30 are designed tominimize wettability by the nicotine solution in order to reduce thelikelihood of nicotine solution leakage via capillarity along thechannels 84 when the heater 14 is not activated, e.g., by applying acoating that is not easily wetted by the nicotine solution.

In yet another alternative embodiment, the central bore 50 may beplugged to prevent leakage of the nicotine solution and an alternativereservoir vent system may be used.

In an alternative embodiment, the elongate wick 30 is associated withthe electric heater 14. In this embodiment, the elongate wick 30′ may bea ceramic material formed with the electronic heater. Indeed, a firedceramic wick 30′ may be used in place of the forming mandrel 62 (FIG.6A) and the green ceramic material may be wrapped around the elongatewick 30′. The resulting combination of wick 30′ and cylindrical electricheater 14′ can be fired together to form an integrated wick/heaterstructure shown in FIG. 11. In this embodiment, a distal end of theelongate wick 30′ extends significantly beyond an end of the cylindricalelectric heater 14′ to enable it to extend into the reservoir 22 in thedisposable cartridge 20 (FIG. 7).

In another alternative embodiment, the elongate wick 30 hassubstantially non-porous support and a capillary structure on an outersurface thereof. The non-porous support may be solid or tubular instructure, depending whether it is desirable to permit air to vent backinto the reservoir.

Container:

The container 88 is useful to provide critical child-resistant safetymeasures to the disposable cartridge(s) 20. In particular, the container88 locks an unused disposable cartridge(s) 20 securely in a package. Inaddition, the container 88 includes empty “waste” chamber(s) sized tocontain a used disposable cartridge 20. The container 88, disposablecartridge 20, and receptacle 18 in the housing 16 all cooperate tosecurely lock the cartridge 20 into either the receptacle 18 or thecontainer 88. This greatly reduces the potential for unintended exposureof an unattached disposable cartridge 20 that contains the nicotinesolution to the environment and/or children. It is desired that theaccess to the nicotine solution contained in the disposable cartridge 20is through use of the ENDS 10 and the conversion of the nicotinesolution to an aerosol. Other access to the liquid contents aredifficult, at best, such as through the destruction of the ENDS 10and/or container 88 containing the disposable cartridge 20.

As shown in FIG. 12A, a modified ENDS 10′ having an extended receptaclesleeve 18′ can be used with the particular embodiment of a containerdescribed below. The steps required to remove an unused disposablecartridge are shown in FIGS. 12B-E.

The container 88 includes at least one first chamber 90 having anopening 91 sized to contain an unused disposable cartridge 20 and atleast one waste chamber 92 having an opening 93 sized to contain a useddisposable cartridge 20. Each unused disposable cartridge 20 ismaintained in a first chamber 90 by a first, releasable engagementmechanism, and each waste chamber 92 has a second engagement mechanismto secure such used disposable cartridge 20, after use.

To insert an unused disposable cartridge 20 into the receptacle 18′ ofan ENDS 10′ housing 16′, the extended receptacle 18′ is placed over anexposed end of the unused disposable cartridge 20. As the extendedreceptacle 18′ is inserted into the first chamber 90 of the container88, the outer surface of the extended receptacle 18′ deflects at leastone retention arm 94, which is securing the cartridge 20 in the firstchamber 90, away from the unused disposable cartridge 20 (FIG. 12C).Retention arm 94 is articulable between a relaxed position extendingtoward the central axis of the first chamber 90 (as shown in FIG. 12B)and a flexed position disposed away from the central axis of the firstchamber 90 (as shown in FIG. 12C). An inwardly-directed flange 96disposed within the extended receptacle 18′, distal the leading endthereof, guides outwardly-biased hooks 98 at the exposed end of theunused disposable cartridge 20 inwardly to permit the flange 96 to pass.Once the flange 96 has passed the unused disposable cartridge 20 hooks98, they return outwardly to securely attach to the flange 96 of thereceptacle 18′ to form a fully-assembled ENDS 10′ (FIG. 12D). Thefully-assembled ENDS 10′ is removable from the first chamber 90 of thecontainer 88 as the retention arms 94 remain flexed outward to permitthe unused disposable cartridge 20 to be removed therefrom (FIG. 12E).

Once the ENDS 10′ has been used, and the nicotine solution is consumed,the used disposable cartridge 20 can be secured into the “waste” chamber92 for disposal. The ENDS 10′ is aligned with the waste chamber 92 asshown in FIG. 13A. The used disposable cartridge 20 can be inserted intothe waste chamber 92 and a set of waste chamber retention arms 100disposed at the base of the waste chamber 92 secure the used disposablecartridge 20 in the waste chamber 92 (FIG. 13B) by engaging a lip 101proximate the mouthpiece 24 of the used disposable cartridge 20. Aprojection 102 disposed at the base 104 of the waste chamber 92 alsobears on one end of the transfer rod 106 to urge it away from themouthpiece 24 to engage the outwardly-biased hooks 98 at the oppositeend of the used disposable cartridge 20 and to deflect them inwardly todisengage them from the flange 96 of the receptacle 18′ on the housing16 (FIG. 13C). With the used disposable cartridge 20 securely locked inthe waste chamber 92, the housing 16′ can be removed from therefrom(FIG. 13C) and an unused disposable cartridge 20 can be coupled to thehousing 16′ for continued use.

FIG. 14 shows a preferred, multi-chambered container 108 having aplurality of first chambers 90′ enclosed with a closure 110, and aplurality of waste chambers 92′. To access a first chamber 90′ toacquire an unused disposable cartridge, a user would remove the closure110 from the opening to expose the unused disposable cartridge.

Additional Alternative Embodiments

The foregoing description has generally described to a series ofembodiments in which the disposable cartridge includes the mouthpiece,outlet, and reservoir, and the heater and vaporization chamber areseparated from the outlet by the reservoir. Alternative embodiments maylocate the heater and vaporization chamber closer to the outlet. Severalof these embodiments will be described below.

In one embodiment shown in FIGS. 15A and B, the ENDS 1000 includes ahousing 1016 containing a power source (not shown) and one or more airinlets (not shown); a reusable mouthpiece 1024 including an electricheater 1014, an air outlet 1025 and a vaporization chamber 1026; anelongate wick 1030; and a disposable cartridge 1020 containing areservoir 1022. The reusable mouthpiece 1024 is removably attachable tothe housing 1016 to permit a disposable cartridge 1020 to be placed inthe ENDS 1000. One of ordinary skill in the art will recognize that ENDS1000 will require an electrical circuit between the electric heater 1014(contained in the mouthpiece 1024) and the power source (contained inthe housing 1016). Therefore, a releasable electrical connection (notshown) is required between the housing 1016 and the mouthpiece 1024. Inthis embodiment, the electric heater 1014 is mounted on a base plate1036, and the base plate 1036 is disposed in facing relation to thedisposable cartridge 1020, when assembled. Thus, in the assembled ENDS1000, the wick 1030 extends from the reservoir 1022, through the baseplate 1036, and into the electric heater 1014. In use, inlet air 1039enters the ENDS 1000 through air inlets (not shown) and passes throughone or more internal conduits 1041 to one or more air passages 1052through the base plate 1036 into the vaporization chamber 1026 where itforms the nicotine aerosol 1044, as described above. The nicotineaerosol 1044 can then be withdrawn from the air outlet 1025 in thereusable mouthpiece 1024.

In one embodiment shown in FIGS. 16A and B, the ENDS 2000 includes ahousing 2016 containing a power source (not shown) and one or more airinlets (not shown); a reusable mouthpiece 2024 including an electricheater 2014 and an air outlet 2025; a vaporization chamber 2026; anelongate wick 2030; and a disposable cartridge 2020 containing areservoir 2022. The reusable mouthpiece 2024 is removably attachable tothe housing 2016 to permit a disposable cartridge 2020 to be placed inthe ENDS 2000. The removable mouthpiece 2024, the disposable cartridge2020 and the base plate 2036 form the vaporization chamber 2026 in theassembled ENDS 2000. One of ordinary skill in the art will recognizethat ENDS 2000 will require an electrical circuit between the electricheater 2014 (contained in the mouthpiece 2024) and the power source(contained in the housing 2016). Therefore, a releasable electricalconnection (not shown) is required between the housing 2016 and themouthpiece 2024. In this embodiment, the electric heater 2014 is mountedon a base plate 2036, and the electric heater 2014 is disposed in facingrelation to the disposable cartridge 2020, when assembled. Thus, in theassembled ENDS 2000, the wick 2030 extends from the reservoir 2022 andinto the electric heater 2014. In use, inlet air 2039 enters the ENDS2000 through air inlets (not shown) and passes through one or moreinternal conduits 2041 to the vaporization chamber 2026 where it formsthe nicotine aerosol 2044, as described above. The nicotine aerosol 2044can then be withdrawn through one or more air passages (not shown)through the base plate 2036 and the air outlet 2025 in the reusablemouthpiece 2024.

In one embodiment shown in FIGS. 17A and B, the ENDS 3000 includes ahousing 3016 containing a power source (not shown); a reusablemouthpiece 3024 including an electric heater 3014, one or more airinlets 3017, an air outlet 3025 and a vaporization chamber 3026; anelongate wick 3030; and a disposable cartridge 3020 containing areservoir 3022. The reusable mouthpiece 3024 is removably attachable tothe housing 3016 to permit a disposable cartridge 3020 to be placed inthe ENDS 3000. One of ordinary skill in the art will recognize that ENDS3000 will require an electrical circuit between the electric heater 3014(contained in the mouthpiece 3024) and the power source (contained inthe housing 3016). Therefore, a releasable electrical connection (notshown) is required between the housing 3016 and the mouthpiece 3024. Inthis embodiment, the electric heater 3014 is mounted on a base plate3036, and the base plate 3036 is disposed in facing relation to thedisposable cartridge 3020, when assembled. Thus, in the assembled ENDS3000, the wick 3030 extends from the reservoir 3022, through the baseplate 3036, and into the electric heater 3014. In use, inlet air 3039enters the ENDS 3000 through air inlets 3017 and enters the vaporizationchamber 3026 perpendicular to the length of the heater where it formsthe nicotine aerosol 3044, as described above. In this embodiment, theair/nicotine aerosol flow is perpendicular to the orientation of theelectric heater 3014. The nicotine aerosol 3044 can then be withdrawnfrom the air outlet 3025 in the reusable mouthpiece 3024.

In one embodiment shown in FIGS. 18A and B, the ENDS 4000 includes ahousing 4016 containing a power source (not shown); a reusablemouthpiece 4024 including an electric heater 4014, one or more airinlets 4017, and an air outlet 4025; a vaporization chamber 4026; anelongate wick 4030; and a disposable cartridge 4020 containing areservoir 4022. The reusable mouthpiece 4024 is removably attachable tothe housing 4016 to permit a disposable cartridge 4020 to be placed inthe ENDS 4000. The removable mouthpiece 4024, the disposable cartridge4020 and the base plate 4036 form the vaporization chamber 4026 in theassembled ENDS 4000. One of ordinary skill in the art will recognizethat ENDS 4000 will require an electrical circuit between the electricheater 4014 (contained in the mouthpiece 4024) and the power source(contained in the housing 4016). Therefore, a releasable electricalconnection (not shown) is required between the housing 4016 and themouthpiece 4024. In this embodiment, the electric heater 4014 is mountedon a base plate 4036, and the electric heater 4014 is disposed in facingrelation to the disposable cartridge 4020, when assembled. Thus, in theassembled ENDS 4000, the wick 4030 extends from the reservoir 4022 andinto the electric heater 4014. In use, inlet air 4039 enters the ENDS4000 through air inlets 4017 and enters the vaporization chamber 4026perpendicular to the length of the heater where it forms the nicotineaerosol 4044, as described above. In this embodiment, the air/nicotineaerosol flow is perpendicular to the orientation of the electric heater4014. The nicotine aerosol 4044 can then be withdrawn from the airoutlet 4025 in the reusable mouthpiece 4024.

The specification and embodiments above are presented to aid in thecomplete and non-limiting understanding of the invention disclosedherein. Since many variations and embodiments of the invention can bemade without departing from its spirit and scope, the invention residesin the claims hereinafter appended.

What is claimed is:
 1. A system for generating a vapor from a liquidcomprising: (a) an electric heater having a body comprising at least onesidewall that defines an interior void, at least one inner surface, atleast one outer surface, and a plurality of apertures through the atleast one sidewall, the electric heater comprising an electricallyresistive material contained within a heat diffusing material, whereinthe heat diffusing material comprises a substantially non-porous ceramicmaterial; and (b) an elongate wick providing a liquid conduit from areservoir to the electric heater, wherein the elongate wick comprises amaterial selected from the group consisting of thermoset polymers,thermoplastic polymers, and ceramics.
 2. The system for generating avapor from a liquid according to claim 1, wherein the elongate wickcomprises heat-resistant thermoplastic polymers.
 3. The system forgenerating a vapor from a liquid according to claim 2, wherein theheat-resistant thermoplastic polymers are selected from the groupconsisting of liquid crystal polymers (“LCP”), Polyetheretherketone(PEEK), Polyether Imide (PEI), Polyphenylene Sulfide (PPS),fluorpolymers, Polyimides, Polyamideimides (PAIs), High-performancepolyamides (HPPAs), Polyimides (PIs), Polyketones, Polysulfonederivatives, Polycyclohexane dimethyl-terephthalates (PCTs),Fluoropolymers, Polyetherimides (PEIs), Polybenzimidazoles (PBIs),Polybutylene terephthalates (PBTs), and Syndiotactic polystyrene.
 4. Thesystem for generating a vapor from a liquid according to claim 1,wherein the electrically resistive material comprises a materialselected from the group consisting of semiconductors, electricallyconductive ceramics, carbon, metals, metal alloys and compositematerials made of a ceramic material and a metallic material.
 5. Thesystem for generating a vapor from a liquid according to claim 4,wherein the semiconductors comprise doped ceramics.
 6. The system forgenerating a vapor from a liquid according to claim 4, wherein theelectrically conductive ceramics comprise molybdenum disilicide.
 7. Thesystem for generating a vapor from a liquid for generating a vapor froma liquid according to claim 4, wherein the carbon comprises graphite. 8.The system for generating a vapor from a liquid according to claim 4,wherein the metals are selected from the group consisting of titanium,zirconium, tantalum, and metals from the platinum group.
 9. The systemfor generating a vapor from a liquid according to claim 4, wherein themetal alloys are selected from the group consisting of stainless steel,nickel-, cobalt-, chromium-, aluminum-titanium-zirconium-, hafnium-,niobium-, molybdenum-, tantalum-, tungsten-, tin-, gallium-, manganese-and iron-containing alloys, and super-alloys based on nickel, iron,cobalt, stainless steel, Timetal® titanium alloy, andiron-manganese-aluminum based alloys.
 10. The system for generating avapor from a liquid according to claim 1, where the semiconductorscomprise doped silicon carbides.
 11. The system for generating a vaporfrom a liquid according to claim 1, further comprising: (a) a housing;and (b) an internal power source operatively connected to the electricheater; wherein the internal power source and the electric heater arecontained within the housing.
 12. The system for generating a vapor froma liquid according to claim 11, wherein the housing provides areceptacle for a disposable cartridge proximate the electric heater. 13.The system for generating a vapor from a liquid according to claim 11,wherein the housing provides for connectivity to an outside electricalsource and/or data communication to supply and/or resupply the internalpower source.
 14. The system for generating a vapor from a liquidaccording to claim 13, wherein the housing provides for the connectivityto the outside electrical source and/or data communication via auniversal serial bus (USB) port.
 15. The system for generating a vaporfrom a liquid according to claim 11, wherein the internal power sourceis a rechargeable battery.
 16. The system for generating a vapor from aliquid according to claim 11, wherein the housing comprises a material,or a combination of materials, or a composite of materials selected fromthe group consisting of metals, alloys, plastics, and ceramics.
 17. Thesystem for generating a vapor from a liquid according to claim 16,wherein the plastics are thermoplastics that are suitable for food orpharmaceutical applications.
 18. The system for generating a vapor froma liquid according to claim 17, wherein the thermoplastics are selectedfrom the group consisting of polypropylene, polyetheretherketone (PEEK)and polyethylene.
 19. The system for generating a vapor from a liquidaccording to claim 12, further comprising a disposable cartridge loadedinto the receptacle.
 20. The system for generating a vapor from a liquidaccording to claim 19, comprising a vaporization chamber formed throughcooperation of the housing, the electric heater, and the disposablecartridge when they are assembled together.